Waveguide based light source

ABSTRACT

A wave guide based light source having a phosphor film with a large two-dimensional extent and a small thickness. The phosphor film is excited by an excitation means.

This application is a continuation application of U.S. application Ser.No. 09/855,254, filed May 15, 2001, now U.S. patent applicationPublication No. 2003/0044160, Published Mar. 6, 2003 (QVIS-01057US1),which claims priority to Provisional Patent Application, S/C No.60/204,645 filed May 17, 2000 (QVIS-01057US0).

FIELD OF THE INVENTION

The present invention relates to a light source comprising a phosphorfilm and a method of concentrating the emitted light.

BACKGROUND OF THE INVENTION

High brightness light sources are needed for many applications includingoptical fiber illumination and image projection. In optical fiberillumination, particularly for telecommunications applications,light-emitting diodes (LEDs), and semiconductor diode lasers are thedominant light sources as described in the article of Hecht, which isattached hereto and incorporated herein by reference (see Hecht, Jeff,Back to Basics: Fiber-optic Light Sources, Laser Focus World, January2000). The output power density of LEDs is generally too low for mostfiber illumination applications. Semiconductor diode lasers have manyfavorable characteristics for fiber illumination. Inexpensive diodelasers are readily available in red or near-infrared wavelengths.However, semiconductor diode lasers suitable for many other applicationsare either not available or very expensive to produce.

For a variety of reasons, lasers and LEDs are rarely used as lightsources for image projection. The primary reason is the high cost oflasers and LEDs capable of producing the high total outputs needed,especially one to several watts of blue light. In addition, coherentlight sources such as lasers can produce artifacts in many projectionapplications. For these reasons the dominant light source for projectionis the arc lamp.

Arc lamps are capable of the brightness and total luminous outputrequired for almost any projection need. Indeed arc lamps are partiallyresponsible for the great success of the movie industry in the 20thcentury. However, arc lamps are considered too expensive for use in manyconsumer devices. In addition, the wide spread use of arc lamps inconsumer devices would pose a new set of safety problems.

In an issued U.S. Pat. No. 5,469,018, which is incorporated herein byreference, a Resonant Microcavity Display was disclosed. A resonantmicrocavity display is a light source incorporating a thin film phosphorembedded in a microcavity resonator. The microcavity resonator consistsof an active region surrounded by reflectors. The dimensions are chosensuch that a resonant standing wave or traveling wave is produced by thereflectors. The methods described lead to the emission of strong andcontrolled radiative modes. This is in contrast to a bare thin filmphosphor (which is not provided in a microcavity) which generates strongemission into waveguide modes (i.e., the emissions travel along thematerial), but only weak and diffuse radiative emissions (i.e., forexample perpendicular to the material).

A light source is formed by coupling an excitation source to themicrocavity structure. The phosphor inside the microcavity may beexcited through several means including bombardment by externallygenerated electrons (cathodoluminescence), excitation by electrodesplaced across the active layer to create an electric field(electroluminescence) or excitation using photons (photoluminescence).

Phosphors in general are restricted in the power density of excitationand emission due to multiple causes. Phosphors are typically insulatingmaterials with relatively low thermal conductivities. In addition, manyphosphors exhibit relatively long emission times which limit the numberof photons each luminescence center may produce in a given time. Due tothese restrictions, phosphors may rarely be excited at levels greaterthan 1 W per square cm resulting in a emission level rarely greater than100 MW per square cm. For these reasons phosphor based devices have beendifficult to utilize in high brightness applications such as fiberillumination or film projection.

SUMMARY OF THE INVENTION

An embodiment of the present invention consists of a relatively largearea of phosphor film excited through, by way of example only,conventional broad area means. The device may be many square centimetersin extent allowing for high power excitation and emission. Theembodiment is formed such that a substantial amount of the light emittedby the phosphor is confined to one or more guided modes with a verysmall cross section. These guided modes exit the device through one ormore regions of similarly small cross section resulting in extremelyhigh brightness.

Other objects and advantages of the present invention will becomeapparent to those skilled in the art from the following detaileddescription of the preferred embodiments, when read in light of theaccompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 illustrates an embodiment of a spiral shaped dual waveguidestructures of the invention.

FIG. 2 illustrates a cross-sectional view of the embodiment of the dualwaveguide structure of FIG. 1.

FIG. 3 illustrates a cross-sectional view of another embodiment of adual wave guide structure with a conducting layer.

FIG. 4 illustrates a cross-section of yet another dual wave guidestructure with a separate wave guide structure located adjacent to thephosphor layer.

FIG. 5 is a side view of one of the dual wave guide channel of FIG. 4.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In the preferred embodiment the construction of the device is such thatthe guided modes have two dimensions which are of the order of awavelength of light. One of these dimensions is given by the thickness12, 14 of the thin film layer 16, 18 involved. This small dimension orthickness 12 can be formed by in-plane patterning.

The other in-plane dimension 20, 22 is sufficiently long in extent toproduce a total area which may be many square centimeters. This one longdimension 20, 22 may consist of spirals or parallel lines so that acircular, rectangle, or other simple shape or surface area issubstantially filled allowing for efficient broad area excitation.

The emitted light travels along the spirals or parallel lines and exitsthe device through “openings” approximately the same size as the smalldimensions 12, 18 of the waveguide. FIG. 1 illustrates this spiralwaveguide and is similar in appearance to a coiled garden hose.

In the simplest embodiment, a spiral is formed on a low index bufferlayer or a low index substrate 24, 26 using standard techniques commonin the semiconductor or holographic optics industry (see Digital OpticsCorporation Standard Program dated Oct. 19, 1994 attached hereto andincorporated by reference). As illustrated in FIG. 2, an example of aspiral embodiment consists of two parallel intertwined channels 24, 26,one recessed below the other by a depth greater than the thickness ofthe waveguide to be formed. In the preferred embodiment, the depth andwidth of these features shall be of the order of a wavelength of thelight to be emitted.

A higher index phosphor layer 16, 18 is deposited onto this substrate24, 26 using any appropriate technique of thin film growth including butnot limited to sputtering or evaporation. This layer may consist of awide range of phosphors (e.g. sulfides, oxides, silicates, oxysulfides,and aluminates) most commonly activated with transition metals, rareearths or color centers. The deposited phosphor layer matches the reliefpattern of the underlying structure so that two spiral waveguides areformed. One waveguide spiral 18 is elevated with a low index mesaunderneath and air, another gas, or a vacuum, on the sides and above.The other waveguide spiral 16 is recessed with low index underneath, lowindex mesas on either side and air, another gas or a vacuum, above. Inother embodiments, a specific high-index waveguide layer may be grownand this layer followed by a layer of phosphor which is formed so as tooptically couple to the waveguide layer.

The guided modes may be confined strictly to the phosphor or may resideprimarily in a separate waveguide adjacent to the phosphor layer with amechanism for coupling guided modes of the phosphor layer to modes ofthe waveguide structure.

FIG. 4 depicts a dual wave guide structure 40 which includes a phosphorwave guide structure 42 and a separate wave guide structure 44 adjacentthereto. In a preferred embodiment, the separate wave guide structure 44is comprised of a fiber optics wave guide structure. It is to beunderstood that the fiber optics wave guide structure can be made withsubstantially fewer impurities than the phosphor wave guide structure.Accordingly, the fiber optics wave guide structure 44 can transmit lightmuch longer distances due to the fact that the absorption problems whichmay be present with the phosphor of that structure are not present withthe fiber optic wave guide structure. The phosphor wave guide structureis coupled to the fiber optics wave guide structure by ramps orreflectors such as the aluminum reflectors as previously discussed andas depicted in FIG. 5. In FIG. 5 the deflector is identified by number46. It is to be understood that in this embodiment, the phosphor waveguide structures 42 can be composed of a multiplicity of discretesegments each with a transition or ramp to the fiber optics wave guidestructure 44. This can increase light output should the phosphor waveguide structure 42 absorb light to a high degree. In this situation thephosphor wave guide structure 42 and in particular each spiral would bedivided into many segments, each with a ramp 46 which would direct thegenerated light to the, preferably continuous, fiber optics wave guidestructure.

In the preferred embodiment FIG. 3, a buffer layer 28, 30 of low indexmaterial is deposited onto the phosphor followed by a conducting layer32 and 34, such as for example an aluminum layer. The buffer layer isbetween the phosphor layer and the conducting layer since although thealuminum conducting layer is principally reflective, it does absorblight, reducing the efficiency of the embodiment. This embodiment allowsthe structure to form an anode for electron beam excitation from the topside. This e-beam excitation may consist of a broad area cathode as isused in vacuum fluorescent displays or field-emission displays (FEDs),or a conventional CRT operated as a flood gun. Appropriate means may beprovided for excitation by other mechanisms.

The inner and outer ends of each spiral may be terminated with tapers orramps as part of the substrate patterned structure or may be cleaved orotherwise formed after growth. Alternatively an aluminum taper at a 45°angle or other appropriate angle can reflect light generated in aphosphorous spiral, for example, a fiber optic wave guide as describedbelow. These outputs from the taper or ramp termination may be combinedusing standard waveguide or fiber optics couplers or may be utilizedseparately. Fiber optics can be made with reflection high purity incomparison to phosphor layer, and thus light generated in the phosphorlayer can be transferred to the fiber optics for substantially loss freecommunication to a desired location. In other embodiments, othertechniques for coupling the light from the waveguides such as wavelengthselective gratings may be used. With such gratings, each light frequencybounces off the grating at a different angle and thus the light can beappropriately separated. Thus the grating can be used to couple lightoutput to other structures, such as other wave guide structures.

It is to be understood that QED principles can be used to enhance thegeneration of light for the wave guide structure.

Industrial Applicability:

A light source for telecommunications applications may be created bycombining the thin film light source with an appropriate modulatorutilizing electro-absorption, electro-optic or other effects. Thewaveguide formed may be specifically designed to allow coupling to atelecommunications fiber. The wide range of phosphors available allowsfor the generation of light at many different wavelengths, in particularerbium doped phosphors may be used to generate light within the lowabsorption band of silica fibers near 1.5 micrometer. Other phosphorsmay be used to generate light within the low dispersion band near 1.3micrometers.

A high intensity light source coupled to a fiber optic may be utilizedfor a variety of medical applications including invasive surgery. Inparticular phosphors may be selected for the specific purposes ofactivating photosensitive compounds, or for interaction with specifictissues, cell types or chemicals.

The high brightness light source of the preferred embodiment may beutilized as an illumination source for an electronic projection display.Separate red, green, and blue sources may be formed and coupled to imageforming devices such as liquid crystal arrays or digital micromirrorarrays. Through modulation of the excitation source or externalmodulation of the generated light, separate color sources may be rapidlyswitched allowing use in a single chip digital micromirror projector. Anarray of small light sources may be formed through patterning so thatseparate light sources are available for each pixel element of an imageforming device. That is to say that each pixel can include a spiral of aphosphor material much as shown in FIGS. 1, 2. If a pixel were onehundred microns across, the spiral would be one hundred microns across.An e-beam could be a source of energy used to excite selected pixels.Each spiral could have a taper, ramp or reflector to reflect thegenerated light perpendicular to that plane of the coil and selectivelyilluminate each pixel. If an addressable excitation source such as araster scanned CRT or an FED is utilized, this array of small lightsources may be utilized to form a display without the imposition of anadditional image forming device. Additionally it is to be understoodthat flood lamps could be used with this technology.

It is to be understood that other embodiments of the invention can bedeveloped and fall within the spirit and scope of the invention andclaims.

1. An apparatus for generating light, comprising: a substrate includinga waveguide pattern thereon; a phosphor deposited upon said substratethat forms a waveguide that matches the waveguide pattern, saidwaveguide having a substantially planar shape and further having awaveguide direction within the plane of the waveguide and an exit regionat an end of the waveguide direction; and wherein the phosphor canreceive excitation energy from an excitation source in a directionsubstantially perpendicular to the plane of the waveguide, and cangenerate light within the phosphor, wherein the light travels in thewaveguide direction and exits the waveguide at the exit region.
 2. Theapparatus of claim 1 wherein said waveguide pattern comprises a spiraland said waveguide direction is a spiral direction.
 3. The apparatus ofclaim 2 wherein said waveguide pattern comprises multiple spiralsconfigured about the same center.
 4. The apparatus of claim 1 whereinsaid excitation source is an electron beam.
 5. The apparatus of claim 1wherein said excitation source is incident light.
 6. The apparatus ofclaim 1 wherein said excitation source is an alternating electric field.7. The apparatus of claim 1 wherein at least one of the dimensions ofthe waveguide is of the order of a wavelength of the generated light. 8.The apparatus of claim 1 wherein mirrors are placed on one or more sidesof the waveguide.
 9. The apparatus of claim 1 including a plurality ofwaveguides, each of which are used within a display to form a displaypixel at their respective exit regions.
 10. An apparatus for generatinglight for use in video display, comprising: one or more substratesincluding a waveguide pattern or patterns thereon; one or more phosphorsdeposited upon said substrates and forming waveguides that matches thewaveguide patterns, said waveguides each having a substantially planarshape and further having a waveguide direction within the plane of thewaveguide and an exit region at an end of the waveguide direction;wherein the phosphors can receive excitation energy from an excitationsource in a direction substantially perpendicular to the planes of thewaveguides, and can generate light within the phosphor, wherein thelight travels in the waveguide direction and exits the waveguide at theexit region; and wherein the output of each waveguide is used to form adisplay pixel at its respective exit region for use within a videodisplay.
 11. A method of generating light, comprising the steps of:providing a substrate including a waveguide pattern thereon; providing aphosphor deposited upon said substrate that forms a waveguide thatmatches the waveguide pattern, said waveguide having a substantiallyplanar shape and further having a waveguide direction within the planeof the waveguide and an exit region at an end of the waveguidedirection; and receiving excitation energy at the phosphor from anexcitation source in a direction substantially perpendicular to theplane of the waveguide, and generating light within the phosphor,wherein the light travels in the waveguide direction and exits thewaveguide at the exit region.
 12. The method of claim 11 wherein saidwaveguide pattern comprises a spiral and said waveguide direction is aspiral direction.
 13. The method of claim 12 wherein said waveguidepattern comprises multiple spirals configured about the same center. 14.The method of claim 11 wherein said excitation source is an electronbeam.
 15. The method of claim 11 wherein said excitation source isincident light.
 16. The method of claim 11 wherein said excitationsource is an alternating electric field.
 17. The method of claim 11wherein at least one of the dimensions of the waveguide is of the orderof a wavelength of the generated light.
 18. The method of claim 11wherein mirrors are placed on one or more sides of the waveguide. 19.The method of claim 11 including a plurality of waveguides, each ofwhich are used within a display to form a display pixel at theirrespective exit regions.